The hard hat is one of the most important personal protection equipment items that can be worn in industrial workplace settings. Many cases and stories from the past have documented the fact that workers have been saved from serious injury or even death because they were wearing head protection. A standard hard hat has two key components - the shell and the suspension system. Both of these components must work together in order for a person to have safe, effective head protection. Like any personal protection item, the components of a hard hat require periodic inspection and maintenance. It's important that companies have programs in place that remind employees to conduct regular inspections. These programs should be structured in such a way that they conform to the needs and requirements of the specific safety considerations and circumstances at the job site.

The shell is typically molded from polyethylene, polycarbonate, or fiberglass. These materials have proven to be durable, reliable and lightweight while also providing effective protection. With the proper care and normal workplace conditions, a hard hat may have a service life of one to two years. The materials used to manufacture head protection gear are susceptible to heat, chemicals, cold temperatures, and sunlight. An employee may be seeing the effects of these elements if they notice discoloration, flakes, stiffness or cracking in the shell. To help minimize the effects from these elements, it's best to store hard hats out of direct sunlight. Choose to carry your head protection in the trunk or in a tool box rather than on the seat or hanging up in the window of a service vehicle. That's especially important for head protection that is only used occasionally by someone visiting a work site. In addition, it is not recommended that hard hats be painted. Always check with the manufacturer before applying anything to head protection because the chemicals in these substances may react adversely with the materials in the hard hat and weaken it.

In addition to any issues found in a routine inspection, any sign of discoloration or wear from the issues above should trigger the immediate replacement. Also, a hard hat that may have been involved in any kind of forceful impact should be replaced immediately. Because head protection is relatively inexpensive, it's always wise to make an investment in new safety equipment if there is any doubt as to its condition. It's also prudent to issue new head protection to any new employee rather than sharing these items. This practice can improve hygiene and make employees more comfortable.

The purpose of the second component to the hard hat, the suspension system, is to help absorb shock from an impact. Therefore, this component is just as critical as the shell and should also be inspected frequently to ensure it's in good condition. Some of the most common areas of wear that may be found in the suspension system are fraying or cuts in the suspension straps or cracking in the plastic headband. Perspiration, oils from a person's hair or normal wear can all be contributing factors to signs of wear and tear. Like the shell, if a user notices any degradation in the suspension system, the hard hat should be replaced immediately. A general guideline from manufacturers is that the suspension system be replaced after 12 months regardless of any visible sign of wear.

By following some simple guidelines related to inspection and care of head protection, companies and workers will be able to perform their work more safely and comfortably.